Self-sealing shingles



Dec. 1, 1964 L- A. BENTON SELFSEALING SHINGLES 2 Sheets-Sheet 1 Filed Dec. 30, 1959 INVENTOR. Louls Afieu rou BY 2 w ATTORNE? Dec. 1, 1964 A. BENTON 3,159,513

SELF-SEALING SHINGLES Filed Dec. '50, 1959 2 Sheets-Sheet 2 27 24 26 A 9b X 22 25 1 I If 20. 5}

INVENTOR. Louis A. BENTON BY g xzz ATTORNEY;

United States Patent 3,159,518 SELF-SEALING SHINGLES Louis A. Benton, Middlesex, Ni, assignor to Johns- Manville Corporation, New York, N.Y., a corporation of New York Filed Dec. 30, 1959, Ser. No. 862,849

7 Claims. (Cl. 156-.-268) ice the roofing material being conveyed, so that the material is severed adjacent the areaof the material which has superimposed thereover a bulge or protuberance in the I protective covering. After cutting of the material into basic shingle is fabricated in a conventional manner, but

it has applied thereto a stripe, band, or globules of adhesive on one of its major faces. The adhesive is always applied on the areas thereof that will be unexposed after application of the shingles as a roof covering. Thus, the adhesive is applied either on the back side of ashingle or onthe portion of the front face of a shingle which will be overlapped by shingles in a subsequent course.

The shingles are nailed to a roof deck in a conventional manner, and they alsoadhere to each other by means of the adhesive stripes, so that a twofold bond is obtained, one mechanical and the other adhesive.

In one type of such self-sealing shingle, a protective covering, such'as, for example, a release paper, is applied over the adhesive stripe prior to packaging of the shingles, so that the stripe does not contaminate or adhere to adjacent shingles during packaging thereof. However, with such a construction, it is necessary that the protective covering for the adhesive be removed prior to application of the shingles as a roof deck covering. In order to avoid difliculties of contamination and adhesion by the adhesive stripe and to simplify the removal. of the release paper by an applicator of the roof covering-prior to application thereof, it is necessary that the protective covering adequately cover the adhesive strips at all portions thereof, and it is also necessary that the protective covering extend over at least one edge of a shingle, whereby the extensions or tabs of the protective covering may be easily and readily gripped for removal of the covering by the shingle applicator. Preferably, the tabs are formed adjacent each of the opposite edges of a shingle so that the protective covering may be removed readily Without additional manipulation of the shingle after its removal from a bundle.

In brief, this invention comprises an asphalt shingle of the self-sealing type having an adhesive stripe superimposed'over a major face thereof, i.e., either the front face or the back side, and the adhesive stripe has super imposed thereover a protective covering, as, for example, a release paper, so that the adhesive'is properly covered to prevent contamination of adjacent shingles or adhesion between shingles while such shingles are packaged. The protective covering is such that it extends beyond opposite edges of each shingle in the form of tabs, whereby either tab can be easily gripped by a shingle applicator for stripping of the covering prior to application of the shingles.

In the manner of application of the protective covering over an adhesive stripe, the covering is applied as a continuous layer over the stripe before the shingles are cut into shingle form and are still in the form of a continuous sheet of roofing material. The protective covering, before being applied over the adhesive layer, has formed therein a plurality of protuberances or bulges, which extend away from the surface of the shingle at spaced points thereof. The shingle cutter is timed with the continuous flow of shingle form, the protective covering between shingles is broken, and since excess protective covering is provided by the formed bulges or protuberances, the excess protective covering overhangs the edges of the shingles in the form of pull or grip tabs. The shingles are packaged in the usual manner, for example, front face-to-back face, and, prior to application, the release paper or protective covering is removed by a shingle applicator, who grabs the covering by one of the tab ends and strips it from the shingle thereby exposing the adhesive stripe.

An object of this invention therefore is to provide an asphalt shingle of the self-sealing type having superimposed on a major face thereof 'a lane or band of adhesive and having superimposed over the adhesive aprotective layer or covering, which extends over the edgesor opposite ends of the shingle in the form of tabs. An additional object of this invention is to provide a method of applying a protectivecovering to'an adhesive stripe of a shingle of the self-sealing type,. so that the adhesive stripe is covered at all portions thereof, and wherebyfthe protective covering extends over the opposite edges of the shingle in the form of pull tabs.

An additional object of this invention is to provide an apparatus for applying a protective covering to an adhesive stripe on a shingle of the self-sealing type, which apparatus applies the protective covering over the stripe not only to cover such stripe properly but also to extend over. the opposite edges of the shingle in theform of pull tabs. V

Still an additional object of this invention is to provide a method of and an apparatus for applying a protective covering over an adhesive stripe of a sheet of material to be formed into shingles of the self-sealing type, whereby the protective covering, when applied as a continuous strip over the-stripe'on the sheet, has a plurality of bulges or protuberances therein.

These and other objects will be readily. apparentfrom the preceding brief description, and the following more detailed description and the appended drawings wherein:

FIG. 1 is a portion of the asphalt shinglefabricating line showing the location of theprotective covering applicator of the instant invention with relation to the shingle cutting machine in the line; 7'

- FIG. 2 is an enlarged view, in elevation, of the protective covering applicator of the instant invention;

FIG. 3 is a view taken along the lines '3-3 of FIG. 2; FIG. 4 is an enlarged view of a detail of the applicator showinglthe mannerof forming the bulges'orjprotuberances in the protective covering and the formation of the areas of weakness in suchbulges or protuberances; and

FIG. 5 is a cross-sectional view of an asphalt shingle showing the protective covering superimposed over the adhesive stripe of the shingle.

Referring to FIG. 1, a portion of an asphalt shingle fabricating system is shown therein. During manufacture, the roofing material, subsequently to form the individual asphalt shingles, is in the form of a continuous sheet 30. The composition of the sheet at this particular stage in the fabricating line, is identical with the compo* sition of a finished asphalt shingle of the self-sealing type. Thus, for example, the sheet comprises a base layer of organic or inorganic felt, saturated with a bituminous coating. The felt also has bituminous coatings adhering thereto on each side thereof; usually the bituminous coating is heavier on one side than on an opposite side, as

the heavier sidehas granules embedded therein to form I the front face or the exposure side of the shingle. Superimposed over a major face of the roofing material, either on the front fact or on the back side, is a continuous band, lane, or stripe of adhesive in the form of a continuous, unbroken or intermittent stripe.

' The continuous sheet of roofing material 30, in its thus finished form, passes through a pair of guide rolls 31, 32 and forms a free loop 30a adjacent to the frame 37 of the fabricating machine. One end of the loop 30a is passed through a guide roll 38, adjacent which the protective covering 2 is applied to the adhesive stripe on the roofing material by the applicator apparatus superposed over the continuous sheet. The protective covering is applied in such a manner that a plurality of bulges or protuberances 2c are formed at spaced predetermined points of the covering, which protuberances or bulges extend away from the adjacent major face of the roofing material. Each bulge has formed therein an area of weakness, whereby the continuous strip of protective covering may be severed or broken by slight tension being applied thereto. After passing through the metering rolls 33, 34, the sheet of material is divided into the proper shingle length by the shingle cutter, which comprises the anvil roll 35 and the cutter roll 36. After passing through the cutter, the sheet 30 is still continuous,

but it has slits therein spaced a shingle length apart. The shingles are then passed through a speed-up section, which may comprise, in part, a pair of guide rolls 39, 40, which rotate at a slightly higher speed than cutting roll 36 and anvil roll 35, thereby placing a slight tension upon 7' V an area of weakness therein. The area of weakness may be a lane of perforations within the protective covering material or may be an area eroded away by the blade 25 from the body of the covering material within the recess.

Upon further rotation of the two rolls, the blade 25 rides out of the recess. The bend 2a, formed in the covering material, retains its integrity after the applicator roll recess 9a and the blade 25 are out of engagement, as the covering material has suflieient body therein to maintain its formed shape. However, if the covering material is very flexible or relatively thin as compared to other covering materials of a similar nature, it may be necessary to apply a suction device within the recess, such that the covering material within recess 9a is held thereagainst. Upon continued rotation of the applicator roll, the material 2 is pressed against the shingle material 30 and in particular over the adhesive stripe to cover the same adequately. After the outer edges of the recess 9a bear against the adhesive stripe during continual application of the covering strip, the bend 2a is transferred as a bulge or protuberance or corrugation 2c in the adhesive covering strip. Such corrugations are continuously formed in the covering material 2 upon each subsequent complete rotation of the applicator roll 9.

Referring back to FIGS. 2 and 3, the applicator roll 9, roll 12, and the unwinding roll frame 1 are mounted on a base frame 11. The latter, by a suitable bearing 11a, is mounted to a drive shaft 21, also provided with suitable bearings 21a. A shaft 10 supports applicator roll 9 and is mounted to the frame 11 by a suitable bearing 14. A shaft 13 supports the tape cutting roll 12 and is supported to the frame 11 from an appropriate bearing 15.

' Timing gears 16, 17, interconnected by chain 16a, are

of the bulge forms a tab for the next shingle to be cut. 7

comes into contact with the applicator roll 9, which superimposes over the adhesive stripe a continuous strip of protective covering 2. Mating with the outer periphery of the applicator roll is the periphery of the tape cutting roll 12, which is of the same diameter and rotates at the same peripheral speed as the applicator roll 9. The

tape 2'is wound around a portion of the periphery of the applicator roll 9 after being unwound from an unwinding stand or a centerless tape magazine 1.

The periphery of the applicator roll 9, referring to FIG. 4, has a recess 9a therein having a wear block 9b at the innermost portion thereof. A recess 22 is formed in the outer periphery of the tape cutting roll 12, such that when the innermost point of the recess 9a is on the line of centers between the two rolls, the longitudinal axis of the recess 22 is also in line therewith. Situated mounted upon shafts 13 and 10 respectively and are ro tated by shaft 10, which is connected to the drive shaft 21 via drums 19, 20 interconnected by a timing belt 18. In the event insufficient pressure is applied by the tape cutting roll 12 upon the applicator roll 9, a spring 42 attached to the frame 11 can be used to bias the shaft 13 toward the shaft 10. The opposite end of spring 42 may be anchored to a bearing housing 41 mounted on the shaft 13.

The entire applicator mechanism is supported by the frame '11, which is in turn supported by the drive shaft 21. Consequently, the applicator roll 9, the tape cutting roll 12, and the frame 11 may be rotated about shaft 21 to an idle position out of the way of the manufacturing line.

The roll of covering material 4 is placed in an unwinding stand 1, which is composed of two approximately cylindrical casings 1a and 1b secured to each other via a hinge 3. The lower casing 1b is mounted to the frame 11 and has an opening at the lower portion thereof to permit egress of the covering material 2, and the upper casing 1a acts'as a cover, which prevents the roll 4 from traveling out of the lower casing during unwinding. After a roll of covering material has been unwound, the lid 1a within the recess is a piston 24 biased to a tape cutting position by spring 26. A cutting blade 25 is secured to the outer extremity of the piston 24, and the limit of travel of the piston is controlled by a retainer bolt 27 passing through a piston slot 24a; a cut-out 28 in the outer periphery of the tape cutting roll 12 is made to properly accommodate the retainer bolt 27. The piston 24 and bolt 27 are positioned relative to each other so that the blade 25 rubs or strikes against the wear block 9b at the formers furthest entrance into the recess 9a.

As shown in FIG. 4, the protective covering material 2, when the recess 9a and the recess 22 are directly opposite each other, is forced into the recess 9a by the cutting blade and by the pinching of the covering material by the edges of the periphery of the cutting roll 12 adjacent the opening 22. The material 2 is also acted upon by the cutting blade, biased by the spring 26, to provide is rotated about the hinge 3, and the core 5 is removed and a new roll inserted. A tension control device may be used to apply the proper tension to the covering material 2 as it unwinds from the roll contained within the stand 1; the tension device may comprise a cradle 7 supporting therein roller 6, which is biased against the unwinding'roll of covering material by a pair of springs 8 secured to the cradle and anchored to the fixed casing 1b.

If desired, the drive shaft 21 may be separately driven by an independent power source, or it may be directly coupled to the rotating cutting roll 36 and the anvil roll 35. If the latter drive is used, the drive shaft 21 would be properly geared to the shaft of either the cutting roll 36 or the anvil roll 35. With either driving source, the point of cutting the sheet 30 into singles and the depositing of the bulge 2c upon the adhesive layer is correlated with the speed of the sheet 30 such that the cutter roll 36 severs the sheet of material 30 at an area subjacent a bulge.

Ordinarily, the guide rolls 33, 34 are rotated at a slightly slower rate of rotation than that imparted tocutter roll 36 and anvil roll 35. As a result, tension is applied to the continuous sheet of material 30; however, since the sheet is continuous, the bulges or protuberances 2c are not leveled out, nor is the protective covering material broken. After passing through the shingle cutter, the proper tension may beapplied tothe sheet 30 to sever the p-rotectivecoveringalong the lane or area of weakness and to separate the shingles from the sheet 30 by passing the slitted sheet 30 through a pair of guide rolls 39, 40, which, in turn, rotate at a slightly higher rate of rotational speed than shingle cutter 36 and anvil roll 35. In a sense, the shingles to be formed are pulled through the shingle cutter and anvil roll, thereby placing tension upon the sheet 30 and the protective covering material. This tensile force is sufiicient to cause the covering strip 2 to break at the area of weakness and to separate the shingle from the sheet.

In the particular installation illustrated and described, the shingle cutter 36 is the lowermost roller, and the sheet of roofing material is situated relative thereto so that the cutter 36 bears against the back side of the roofing material while the anvil roll 35 bear-s against the granule or face side of the roofing material. The rotational speed of rolls 35 and 36 and roll 9 are adjusted in such a way that a cutting edge on the periphery of the roll 36 cuts the sheet of roofing material at an area adjacent a bulge 2c. The cutter roll 36 and the anvil roll 35 are of the type commonly used to cut the sheet 30 into shingles, with which cutter roll 36 does not come into direct contact with the periphery of the roll 35. Consequently, the sheet 30 is cut only partially through at the cutter. Complete separation is effected by a speed-up section, as for example, the section comprising guide rolls 39, 40, which applies tension to the sheet. Since the cutting blade enters the sheet of material from the bottom thereof and. the bulge 2c is formed away from the upper portion thereof, the strip of covering material 2 is not affected in any Way by the cutting of the sheet of material 30.

Referring to FIG. 5, the resultant shingle 30b hasthe adhesive stripe 30c superimposed over the face granules 30d on the exposure side to form a continuous lane of adhesive superposed thereover. The strip fully covers the adhesive stripe 300 on all sides and also has its opposite end-s extending over opposite edges of the shingle, whereby such overhanging ends form pull or gri-p tabs making the covering strip readily accessible for stripping prior to roof deck application of the shingle.

The composition of the adhesive may be of the type wherein the stripe may exhibit predominately heat sensitive characteristics or pressure sensitive characteristics, or it may be a mixture of adhesives which exhibit both, heat sensitive and pressure sensitive characteristics. The art of self-sealing shingles has been sufiiciently developed so that the compositions of the various adhesives suitable for use on shingles are well-known.

The materialcornprising the covering strip 2 may take many forms. It may be in the form of a release paper.

For example, a 40 pound sulfite paper coated on one side with a baked silicone release coating would be satisfactory. Such a paper is manufactured by the Daubert Chemical Company of Chicago, Illinois. In addition, the covering strip may be made from metallic sheeting, as, for example, aluminum foil, and silicone treated metallic foil. The covering strip, per se, is not a part of this invention, and the term, covering strip, is used in its broadest sense to include all types of treated or untreated paper, cloths, and metallic sheets suitable for use as protective coverings for the particular adhesive used on the shingle.

While the invention has been described in rather full detail, it. will be .understood that these details need not be strictly adhered to and that various changes and modifications may suggest themselves to one skilled in the art, all falling within the scope of the invention as defined by the subjoined claims.

What I claim is:

l. A method of manufacturing asphalt roofing shingles, comprising the steps of feeding a web of fabricated shingle material having a lane of adhesive thereon extending substantially lengthwise of the. web, covering the adhesive lane with a strip of release material having a plurality of longitudinally separated portions extending transversely of the strip, said portions being spaced from the adhesive lane and the web, and transversely severing the web and the strip at said spaced portions of the strip, whereby each shingle is provided with a strip of release material having a tab portion extending beyond an edge of the shingle.

2. A method of manufacturing asphalt roofing shingles, comprising the steps of feeding a web of fabricated shingle material having a lane of adhesive thereon extending substantially lengthwise of the web, covering the adhesive lane with a strip of release material having a plurality of longitudinally separated portions extending transversely of the strip, said portions being spaced from the adhesive lane and the web and having a weakened area, transversely weakening the web along lines aligned with the spaced portions, and tensioning the web and strip to an extent sufiicient to break both the web and the strip along their weakened areas.

3. A method of manufacturing asphalt roofing shingles,

comprising the steps of feeding a web of fabricated shingle material having a lane of adhesive thereon extending substantially lengthwise of the web, feeding a strip of release material of a width to cover the lane of adhesive at a speed correlated with the speed of the web, corrugating the strip transversely thereof at predetermined spaced intervals, covering the adhesive lane with the strip of release material, and severing the web and the strip along transverse lines aligned with the corrugations, whereby each shingle is provided with a strip of release material having a. tab portion extending beyond an edge of the shingle.

4. A method of manufacturing asphalt roofing shingles, comprising the steps of feeding a web of fabricated shingle material having a lane of adhesive thereon extending substantially lengthwise of the web, feeding a strip of release material of a width to cover the lane of adhesive at a speed correlated with the speed of the web, corrugating the strip transversely thereof at predetermined spaced intervals, weakening the strip along the corrugations, covering the adhesive lane with the strip of release material, weakening the web along lines extending transversely thereof and aligned with the corrugations, and tensioning the web and strip to an extent sufiicient to break both the web and strip along their weakened portions.

5. Apparatus for manufacturing asphalt shingles, comprising means for feeding a web of shingle material having a lane of adhesive thereon extending substantially lengthwise of the web, means for feeding a strip of release material of a width to cover the lane of adhesive, the speed of the strip feeding means being correlated with the speed of the web feeding means, means for transversely corrugating the strip at spaced intervals along its length, means for applying the strip over the lane of adhesive on the web, and means for severing the web and the strip along transverse lines aligned with the corrugations.

6. Apparatus for manufacturing asphalt shingles, comprising means for feeding a web of shingle material having a lane of adhesive thereon extending substantially lengthwise of the web, means for feeding a strip of release material of a width to cover the lane of adhesive, the speed of the strip feeding means being correlated with the speed of the web feeding means, means for transversely corrugating the strip at spaced intervals along its length and for weakening the corrugations, means for applying the strip over the lane of adhesive on the web, means to weaken the web along transverse lines aligned with the corrugations in the strip, and means for tensioning the .web and strip to an extent sufiicient to break both the web and the strip along their weakened portions.

7. Apparatus for manufacturing asphalt shingles as recited in claim 6, wherein the means for corrugating and weakening the strip of release material comprises a pair of mating rolls feeding the strip therebetween, one roll having a radially extending blade, and the other roll having a recess mating with the blade, whereby the strip is crimped and weakened by the action of the blade in the recess.

References Cited in the file of this patent UNITED STATES PATENTS 10 2,491,281 Rowe Dec. 13, 1949 2,632,494 Agee Mar. 24, 1953 2,644,779 Manning July 7, 1953 

1. A METHOD OF MANUFACTURING ASPHALT ROOFING SHINGLES, COMPRISING THE STEPS OF FEEDING A WEB OF FABRICATED SHINGLE MATERIAL HAVING A LANE OF ADHESIVE THEREON EXTENDING SUBSTANTIALLY LENGTHWISE OF THE WEB, COVERING THE ADHESIVE LANE WITH A STRIP OF RELEASE MATERIAL HAVING A PLURALITY OF LONGITUDINALLY SEPARATED PORTIONS EXTENDING TRANSVERSELY OF THE STRIP; SAID PORTIONS BEING SPACED FROM THE ADHESIVE LAND AND THE WEB, AND TRANSVERSELY SEVERING THE WEB AND THE STRIP AT SAID SPACED PORTIONS OF THE STRIP, WHEREBY EACH SHINGLE IS PROVIDED WITH A STRIP OF RELEASE MATERIAL HAVING A TAB PORTION EXTENDING BEYOND AN EDGE OF THE SHINGLE. 